Reloadable containerized system for wet and dry proppants and methods of making and using same

ABSTRACT

A system for reloading a container with proppant. The system includes a transloader having a conveyer belt and a discharge device. The system includes a reloading system comprising a bulk material storage bin having a proppant receiving area, a funnel having an expandable loading tube, and a gate for controlling flow of the proppant from the funnel into the container. The system comprises a reloader comprising a loading bay having a load cell and the container disposed on the load cell.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/659,027, titled “Reloadable Containerized System for Wet and DryProppants and Methods of Making and Using Same,” which was filed on Apr.13, 2022 and is pending and claims priority to U.S. Provisional PatentApplication, Ser. No. 63/175,450, titled “Systems and Methods forReloading Material Storage Containers,” and filed Apr. 15, 2021. Thedisclosure of each application is incorporated by reference herein inits entirety.

BACKGROUND

During drilling operations for oil and gas wells, hydraulic fracturingoperations are often utilized to increase the production from the well.During such hydraulic fracturing operations, a hydraulic fracturingfluid comprising a mixture of fluids, chemicals, and proppants isblended and pumped into the well bore. The particular composition of ahydraulic fracturing fluid can vary from well to well. Further, becauseof the highly abrasive nature of the fracturing fluid, the fracturingfluid is typically blended at the well site in a blender rather thanbeing pumped from offsite. Accordingly, the necessary components for thefracturing fluid must be present at the well site. Storing thesecomponents, and particularly the wet or dry proppants, presents uniquechallenges to ensure that the fracturing operations are able to proceedefficiently and cost-effectively.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding of some aspects of the disclosure. Thissummary is not an extensive overview of the disclosure. It is notintended to identify critical elements of the disclosure or to delineatethe scope of the disclosure. Its sole purpose is to present someconcepts of the disclosure in a simplified form as a prelude to the moredetailed description that is presented elsewhere herein.

In some aspects, the techniques described herein relate to a method forreloading a container with proppant. A method comprises providing asystem for reloading containers. The system includes a transloaderhaving a conveyer belt and a discharge device, and a reloading system.The reloading system comprises a bulk material storage bin having aproppant receiving area, a proppant dispensing device having anexpandable loading tube, and a gate. The system further includes areloader having a loading bay including a load cell. The method includesdisposing the proppant onto the conveyer belt and causing the dischargedevice to discharge the proppant into the bulk material storage bin. Themethod comprises situating the container in the loading bay atop theload cell. The method includes opening the gate and causing theexpandable loading tube to expand to deliver the proppant from the bulkmaterial storage bin into the container. The method comprises removingthe container from the loading bay after a weight of the containerreaches a predetermined weight.

In another embodiment, a system for reloading a container with proppantcomprises a transloader having a conveyer belt and a discharge device.The system includes a reloading system comprising a bulk materialstorage bin having a proppant receiving area, a funnel having anexpandable loading tube, and a gate for controlling flow of the proppantfrom the funnel into the container. The system comprises a reloadercomprising a loading bay including a load cell and the containerdisposed on the load cell.

In yet another embodiment, a method for reloading a container withproppant comprises providing a system for reloading containers. Thesystem comprises a transloader having a conveyer belt and a dischargedevice, and a reloading system. The reloading system includes a bulkmaterial storage bin having a proppant receiving area, a proppantdispensing device having an expandable loading tube, and a gate. Thesystem further includes a reloader comprising a loading bay including aload cell. The method includes causing the discharge device to dischargethe proppant into the bulk material storage bin, situating the containerin the loading bay, and causing the expandable loading tube to expand todeliver the proppant from the bulk material storage bin into thecontainer.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the disclosure are described in detail belowwith reference to the attached drawings.

FIG. 1 is a schematic illustration of a system for reloading storagecontainers according to embodiments of the disclosure.

FIG. 2A illustrates a bulk material storage bin of the system of FIG. 1.

FIG. 2B is a bottom view of the bulk material storage bin of FIG. 2A.

FIG. 2C is a front view of a funnel of the bulk material storage bin ofFIG. 2A.

FIG. 3 is a perspective view of a reloader of the system of FIG. 1according to embodiments of the disclosure.

FIG. 4 illustrates a front view of a bulk material storage bin assupported by a reloader according to embodiments of the disclosure.

FIGS. 5A and 5B are side views of the bulk material storage bin assupported by the reloader according to embodiments of the disclosure.

FIG. 6 is a schematic of an automated control system for operating thebulk material storage bin, a transloader, and a reloader of the systemfor reloading storage containers of FIG. 1 , according to embodiments ofthe disclosure.

FIG. 7 is a flow diagram of a method of operating a reloading systemaccording to embodiments of the disclosure.

DETAILED DESCRIPTION

Many different storage systems exist for storing proppants for hydraulicfracturing operations. In one example, a silo-style system incorporatesa plurality of silos that are transported to a well site where the silosare erected and filled with proppant. The proppant may be delivered tothe well site via a truck and trailer, and then conveyed orpneumatically transferred the silos for storage. When the time comes tohydraulically fracture the well, the proppant is dispensed from thesilo(s) onto a conveyor or gravity fed and into the blender where it ismixed with water and other chemicals before being sent downhole. Thesilo systems are beneficial because they offer higher payload comparedto other containerized systems. However, the silo systems are expensive,loading systems can be unreliable, and may require specialty equipmentin order to erect and/or operate the system.

Containerized storage systems utilize smaller containers to transportand store proppant. Such systems are less expensive and can be saferthan silo systems when it comes to reducing silica dust, for example.Additionally, containerized systems are more versatile, as thecontainers can be more easily moved between locations, and can even bedirectly coupled to the blender preventing the need for proppantconveyors (and therefore reducing silica dust). However, the containersare not able to hold as much proppant with holding capacities rangingfrom about 12 tons of proppant per box to around 25 tons of proppant perbox. Additionally, containers often require specialized trailers fortransport and/or discharge of proppant at the well site. In order toprovide the required amount of proppant for a fracking operation, manydelivery trucks may be required to deliver numerous containers,sometimes over 100 boxes, increasing the possibility for accidents. Onceon location, the storage area for the boxes may be 10,000 square feet ormore.

Systems and methods for utilizing a reloadable containerized storagesystem for a hydraulic fracturing operation are described herein.According to embodiments of the disclosure, a containerized systemutilizes a plurality of containers known to the industry for storingproppant. A reloading system allows the containers to be reloaded suchthat fewer containers are required to be stored at the wellsite.Transportation of proppant to the reloader can be accomplished with anystyle of bulk material trailer including but not limited to grain styleand pneumatic style trailers. Payloads with such trailers can be higherthan traditional containerized sand trailers reducing the number ofloads to location and environmental impact. Thus, the system blends theefficiencies of silo systems with the reliability and versatility of boxsystems.

Referring to FIG. 1 , a system 100 for reloading proppant containersincludes a delivery vehicle 102, a transloader 104, and a reloadingsystem 106. The reloading system 106, described in detail below,generally includes a bulk material storage bin 110 and a reloader 130.In a highly generalized summary, proppant P for use in hydraulicfracturing operations is delivered to a wellsite via the deliveryvehicle 102 and offloaded onto the transloader 104 which deposits theproppant P into the reloading system 106 for reloading containerizedproppant units (or simply “containers”) 150. The flow of proppant P fromthe vehicle 102 to the reloading system 106 is represented by the arrowsin FIG. 1 . One or more components of the system 100 may be in datacommunication with and controllable by an automated control system 200(FIG. 6 ), described in more detail herein.

The proppant P may be dry proppant DP or wet proppant WP. The moisturecontent of the proppant P may impact the flow of the proppant P from thebulk material storage bin 110 into the container 150 (e.g., all otherthings being equal, wet proppant WP may flow from the bulk materialstorage bin 110 into the container 150 at a slower rate than dryproppant DP, and wet proppant WP may have a higher likelihood of gettingjammed in the bulk material storage bin 110 relative to dry proppantDP). In embodiments, certain features and workings of the system 100 maybe adaptively modified based on the moisture content of the proppant P.In other embodiments, one reloading system 100 may be configuredexclusively or primarily for dry proppant DP and another reloadingsystem 100 may be configured exclusively or primarily for wet proppantWP, in line with the teachings of the present disclosure. The term “wetproppant,” as used herein, refers to proppant P with a moisture contentgreater than or equal to one percent. The moisture content may bemeasured using Equation 1 below or using other suitable methods known inthe art or developed in the future.

$\begin{matrix}{{{moisture}{content}{of}{soil}} = \frac{( {{{weight}{of}{moist}{soil}} - {{weight}{of}{dry}{soil}}} )}{{weight}{of}{dry}{soil}}} & {{Equation}1}\end{matrix}$

For instance, if the weight of moist soil is 102 g and the weight of drysoil is 90 g, the moisture content of this proppant P is 0.133 or 13.3%.As such, this proppant P may be characterized as wet proppant WP.

The delivery vehicle 102 can be any vehicle configured to deliverproppant P to the wellsite, such as a grain trailer, pneumatic trailer,and the like. Because the delivery vehicle 102 does not need to bespecially configured, any available delivery vehicle, or multiple typesof delivery vehicles, may deliver proppant to the wellsite. This isbeneficial because the operator is not limited by the availability ofspecific types of trailers or drivers for such trailers. Typically,however, the trailer will have a hopper bottom designed for offloadingmaterial at the well site.

The transloader 104 may have a conveyer belt 104A, a discharging device104B, a moisture content reader 104C, and a controller 104D.

The transloader 104 may be any conveyor-type known to those of skill inthe art, for example, an RBT-style transloader, mobile conveyor orauger, or any other conveying mechanism. Regardless of the type, thetransloader 104 receives the proppant material P from the deliveryvehicle 102 and, via the conveyer belt 104A and discharging device 104Bthereof, conveys the proppant material P to the reloading system 106.Specifically, the conveyer belt 104A may convey the proppant material Pto the discharging device 104B and the discharging device 104B mayconvey the proppant material P to the bulk material storage bin 110 ofthe reloading system 106. The proppant P may ultimately be conveyed fromthe bulk material storage bin 110 of the reloading system 106 to thecontainer 150 as set forth herein.

The discharging device 104B may be located at a distal end of thetransloader 104 and may optionally be selectively movable in order todischarge the proppant P into a particular area of the bulk materialstorage bin 110. The discharging device 104B is discussed in more detailwith reference to FIG. 4 .

The moisture content reader 104C may be located on the conveyer belt104A of the transloader 104 and/or elsewhere (e.g., on the dischargingdevice 104B, within the bulk material storage bin 110, et cetera). Themoisture content reader 104C may be any suitable sensor now known ordeveloped in the future that allows for the moisture of the proppant Pto be determined, e.g., so as to distinguish between wet proppant WP anddry proppant DP. In embodiments, the readings of the moisture sensor104C may be fed to the controller 104D in a wired or wireless manner.The moisture content reader 104C may, in embodiments, comprise agrouping of moisture sensors that are placed on the transloader 104and/or reloading device 106.

The controller 104D may control the operation of the transloader 104based, e.g., on input from the automated control system 200. Forexample, the controller 104D may control the operation of the conveyerbelt 104A (e.g., start, stop, speed up, or slow down the belt 104A)and/or control the operation of the discharging device 104B (e.g., causethe discharging device 104B to convey proppant P to a particular area ofthe bulk material storage bin 110) based on input from the automatedcontrol system 200. The controller 104D may, in embodiments, use thereadings from the moisture content reader 104C to identify the proppantP as one of wet proppant WP and dry proppant DP and communicate same tothe automated control system 200. In other embodiments, the controller104D may communicate the reading of the moisture content reader 104C tothe automated control system 200 and the automated control system 200may determine whether the proppant P is to be categorized as dryproppant DP or wet proppant WP.

As noted above, the reloading system 106 broadly includes a bulkmaterial storage bin 110 and a reloader 130. The bulk material storagebin 110 is a storage vessel for holding and dispensing proppant materialP to the containers 150, and may be configured to temporarily store atleast 50 tons of proppant. In embodiments, the bulk material storage bin110 may hold 60, 70, 80, 90, or 100 or more tons of proppant.

Referring now to FIGS. 2A and 2B, the bulk material storage bin 110includes a proppant receiving area 110A and a proppant dispensing area110B. The proppant dispensing area 110B may be proximate the reloader130 relative to the proppant receiving area 110A. Proppant P may bedelivered by the transloder 104, and specifically the discharging device104B thereof, to the proppant receiving area 110A of the bulk materialstorage bin 110. The proppant P may flow from the proppant receivingarea 110A down into the proppant dispensing area 110B and into one ormore of the containers 150. The flow of the proppant P from the bulkmaterial storage bin 110 into the containers 150 may be due to gravity,and as discussed herein, may be aided by vibration devices and the likeas appropriate. The surfaces of the bulk material storage bin 110 may beconfigured to ensure that the proppant P flows from the bulk materialstorage bin 110 into the containers 150 at an appropriate rate such thatthe containers 150 are filled quickly and efficiently without spillage.

The proppant dispensing area 110B may comprise one or more funnels (orproppant dispensing devices) 111. While four funnels 111 are shown inFIG. 2A, it shall be understood by those of skill in the art that thebulk material storage bin 110 may have fewer than four (e.g., one two,or three—such as shown in FIG. 1 ) or greater than four (e.g., five ormore) funnels 111. Each funnel 111 defines an opening 112 in the bottomof the bulk material storage bin 110 through which proppant P ispermitted to flow.

A gate 116 covers each of the openings 112. Each gate 116 may beconfigured as a knife gate, butterfly gate, or the like. The gate 116may be coupled to a regulator 118 (FIG. 2B) that is operable to open andclose the gate 116 to control the flow of proppant P from the bulkmaterial storage bin 110. The regulator 118 may be controlledhydraulically, pneumatically, electrically, or otherwise as is known tothose of skill in the art. As described below, the regulator 118 may bein communication with the automated control system 200 (FIG. 6 ) thatcontrols the regulator 118, and therefore, the position of the gate 116.

A loading tube 120 may be secured around the opening 112 of each funnel111, and may be designed to expand and contract to deliver proppant Pfrom the bulk material storage bin 110. A distal end 120D of the loadingtube 120 may include a diffuser 122, such as a witch's hat, to aid inspreading the discharged proppant P. The diffuser 122 may facilitate theeven spread of the discharged proppant P into the container 150. Inembodiments, the expansion and contraction of the loading tube 120 maybe controlled via the automated control system 200.

As shown in FIG. 2A, the bulk material storage bin 110, and specificallythe proppant receiving area 110A thereof, may optionally be equippedwith one or more partitions or dividers 114 separating the vessel 110into sections 115A, 115B, and 115C. Each section 115A, 115B, and 115Cmay have associated therewith a solitary funnel 111 or a grouping offunnels 111. The sections 115A, 115B, and 115C may receive differentproppant materials P for use in the fracking fluid (e.g., section 115Aand section 115B may receive proppant P having different moisturecontents). Two partitions 114 are disclosed in the figures; however, itwill be understood by those of skill in the art that a single partition114, or more than two partitions 114, may be situated within the bulkmaterial storage bin 110 to create sections for receiving differenttypes of proppant materials.

The dividers 114, where employed, may be removable or may be fixed.Where the dividers 114 are removable, the bulk material storage bin 110may be divided into one or more sections in line with the requirementsof the job. For example, a divider 114 may be employed to create asection for housing and dispensing dry proppant DP and another sectionfor housing and dispensing wet proppant WP. Dividers 114 may likewise beused to guide the proppant P into a particular container 150. As such,different sections of the bulk material storage bin 110 may have thesame type of proppant P.

The bulk material storage bin 110 may comprise one or more measurementdevices 113A and one or more actuating devices 113B. The measurementdevices 113A and the actuating devices 113B may be situated in theproppant receiving area 110A, the proppant dispensing area 110B (e.g.,proximate the gate 116), and/or at another suitable location inside thebulk material storage bin 110.

In embodiments, at least one measurement device 113A and at least oneactuating device 113B may be associated with each funnel 111. Thus,while FIG. 2A shows one measurement device 113A and one actuating device113B associated with each funnel 111, in embodiments, two or a differentnumber of measurement devices 113A and two or a different number ofactuating devices 113B may be associated with each funnel 111. Inembodiments, one funnel 111 may have a different number of measurementdevices 113A or actuating devices 113B associated with it relative toanother funnel 111. In some embodiments, one or more measurement devices113A and/or actuating devices 113B may be omitted.

The measurement device 113A, in embodiments, is a sensing device thatallows for the determination of a property of the proppant P associatedwith a particular funnel 111 and/or a section (e.g., section 115A) ofthe bulk material storage bin 110 associated with that funnel 111. Themeasurement device 113A may, e.g., be a contact and/or non-contactheight sensor, a volume-determining device, or other appropriate devicefor determining at least one property of the proppant P associated witha particular funnel 111 or section. For example, the measurement device113A may be a mechanical height sensor, a radar level measurementdevice, an ultrasonic level sensor, a LIDAR volume sensor, et cetera.The measurement device 113A may, for instance, allow for a height and/orvolume of proppant P in the funnel 111 to be determined, so as to ensurethat the area of the material storage bin 110 associated with themeasurement device 113A is not overfull with proppant P or has aninadequate amount of proppant P.

The actuating device 113B may be any device configured to facilitate theflow of proppant P from the material storage bin 110, e.g., the funnel111 thereof, into the container 150. The actuating device 113B may,e.g., be a pneumatic vibrator device, an electrical vibrator device, orother suitable device configured to urge the proppant P from the bulkmaterial storage bin 110 into the container 150. The actuating device113B may be controlled by the automated control system 200. Theactuating device 113B may further be actuated manually by an operator asdesired.

The bulk material storage bin 110 may include a controller 113C, whichmay be housed within the bulk material storage bin 110 or at a suitablelocation outside the bulk material storage bin 110. The controller 113Cmay be in data communication with the automated control system 200, andmay interact with the measurement device 113A, the actuating device113B, and/or the regulator 118. For example, the controller 113C mayconvey measurements taken by the measurement device 113A to theautomated control system 200 and control the actuating device 113Band/or the gate 116 based on directions provided by the automatedcontrol system 200. For instance, where the measurements from themeasurement device 113A indicate that the proppant P is not flowingthrough the funnel 111 into the container 150 or is flowing downstreamat too slow a rate (e.g., at less than 1000 lbs per 30 seconds), theautomated control system 200 may cause the controller 113C to activatethe actuation device 113B to speed up the flow of proppant P into thecontainer 150 and/or cause the regulator 118 to more fully open the gate116.

The automated control system 200 may further control the operation ofthe transloader 104 based on input from the measurement device 113A. Forinstance, where the measurement device 113A indicates that a particularsection (e.g., section 115A) is nearing capacity, the automated controlsystem 200 may cause the discharging device 104B of the transloader 104to discharge proppant P to a different section (e.g., section 115B).

The automated control system 200 may also regulate the speed of thetransloader conveyer belt 104A based on the measurements taken by themeasurement device(s) 113A. For example, where the measurement devices113A indicate the bulk material storage bin 110 is nearing capacity(e.g., the bulk material storage bin 110 is at 85% capacity), theautomated control system 200 may, in communication with the transloadercontroller 104D, reduce the speed of the conveyer belt 104A and generatean alarm (e.g., an audible alarm, a visual alarm, an electroniccommunication delivered to a mobile device of an operator, et cetera) sothat operation of the system 100 may be evaluated. The automated controlsystem 200 may further halt the conveyer belt 104A where themeasurements from the measurement devices 113A indicate the bulkmaterial storage bin 110 is at capacity.

FIG. 2C shows an example funnel 111 in more detail. Each funnel 111 maybe symmetrical (e.g., a left half of the funnel 111 may be a mirrorimage of the right half thereof). Alternately, the shape of the funnel111 may be irregular and may be configured in line with the particularapplication. Not all funnels 111 need to be identical.

In embodiments, each funnel 111 may have at least one angled wallsection 111A and one angled wall section 111B. The angled wall section111A may make an exterior angle a with a horizontal plane H and theangled wall section 111B may make an exterior angle β with thehorizontal plane H. The angle α may, in embodiments, be disparate fromthe angle β.

While not required, the angles α and β of the wall sections 111A and111B, respectively, may be adjustable. For example, where the proppant Pis determined to be dry proppant DP, at least one of the angle α and theangle β may be set to about thirty degrees (30°) as these angles αand/or β may allow for the dry proppant DP to freely flow from thematerial storage bin 110 to the container 150 at the appropriate rate.Alternately, where the proppant P is determined to be wet proppant WP,one or both of the angles α and β may be increased, e.g., to about fortydegrees (40°) or more. The increased slope of the wall sections 111Aand/or 111B may ensure the wet proppant P travels into the appropriatecontainer 150 at the desired rate despite the moisture content of theproppant P.

The wall sections 111A and/or 111B, and therefore the angles α and/or β,may be adjusted manually. Alternately, the wall sections 111A and/or111B may be motorized and a user may set the angles 60 and/or β or theautomated control system 200 may automatically set these angles based,e.g., on the moisture content of the proppant P and its flow rate intothe container 150. In other embodiments still, the wall sections 111Aand/or 111B may be fixed. In these embodiments, a bulk material storagebin 110 may be created for dry proppant DP and a separate bulk materialstorage system 110 may be created for wet proppant WP such that theangles α and/or β of the wet proppant material storage system 110 aregreater than the angles 60 and/or β of the dry proppant material system110. In some embodiments, certain funnels 111 of a solitary bulkmaterial storage bin 110 may be designed for wet proppant WP and otherfunnels 111 of that same bulk material storage bin 110 may be designedfor dry proppant DP.

Other changes may likewise be made to the system 100 based on whetherthe proppant P is dry proppant DP or wet proppant WP. For example, wherethe reloading system 100 is configured for wet proppant WP, the surfacesof one or more components that are to come into contact with the wetproppant WP may be coated with anti-friction coatings to reduce proppantsurface tension and facilitate the flow of the wet proppant WP from thetransloader 104 ultimately into the container 150.

Moving on to FIGS. 3-5B, the bulk material storage bin 110 may besupported on the reloader 130. The reloader 130 includes a frame 132defining a receiving area 134. The frame 132 has a bottom surface 135that contacts the ground when in use, and a platform surface or channelguide 136 for supporting one or more containerized proppant units 150. Aplurality of partitions 138 may extend between the platform surface 136and a top of the frame 132 thereby defining a plurality of individualreloading (or loading) bays 140A, 140B, and 140C. While three reloadingbays (generally 140) are shown in FIG. 3 , it shall be understood thatthe reloader 130 may have greater than or fewer than three reloadingbays. For example, in FIG. 4 , the reloader 130 is shown as having fourreloading bays 140A-140D. The reloader 130 may, in embodiments, have asolitary reloading bay.

The bulk material storage bin 110 may be lifted to a position atop thereloader 130 using any lifting mechanism, including but not limited to aforklift, standard loader, crane, et cetera, such that each of thefunnels 111 extends generally into (or above) a respective reloading bay140A, 140B, or 140C.

Each reloading bay 140 may include a load cell 142 configured to receivea container 150. The load cell 142 measures a weight of the container150 in real time. The load cell 142 may be incorporated into aone-size-fits-all table that can receive any container 150. Inembodiments, the load cell 142 may be incorporated into an adjustablechannel guide configured to receive multiple types of containers 150.Regardless, the load cell 142 may be in operable communication with theautomated control system 200 to control the flow of the proppant out ofthe bulk material storage bin 110 and into the respective container(s)150 based at least in part on the weight of the respective container(s)150. In other words, each load cell 142 measures the weight of therespective container 150, and the position of the gate 116 (i.e., open,partially open, or closed) may be automatically controlled based on theweight of the container 150. Further, the actuating device 113B may beactivated where the measurements from the load cell 142 indicate thatproppant P is not flowing into the container 150 at a suitable rate.

Each empty container 150 may be placed into a respective reloading bay140 using, for example, a forklift. When the container 150 is placed inthe reloading bay 140, a releasing mechanism (e.g., hooks, magnets,etc.) on the reloader 130 may automatically open a fill port or hatch152 on the container 150 such that the container 150 can receiveproppant from the bulk material storage bin 110.

To receive the proppant, the loading tube 120 may expand downwardlytoward the open fill port in the container 150. As illustrated in FIG. 4, in embodiments, the loading tube 120 may expand into the container 150through the open fill port, thereby reducing the amount of silica dustcreated by movement of the proppant. The tube 120 may have a sealingring (e.g., rubber, fiber, etc.) that is configured to form a seal ontop of the container 150 to reduce the amount of silica dust. Theautomated control system 200 may control the position of the loadingtube 120 relative to the container 150. In embodiments, the loading tube120 may automatically lower when an empty container 150 (e.g., asdetermined by the load cell 142) is placed into a reloading bay 140 andmay automatically raise when the container 150 is filled.

When the load cell 142 determines that the container 150 is full, thegate 116 may be closed and a light 155 on the reloader 130 above therespective reloading bay 140 may be activated to alert a user that thecontainer 150 is filled and ready to be removed from the reloader 130.As described in greater below, a display may convey the weight of thebox and may correspond with a computing device, such as a tablet orcomputer. Additionally, as the container 150 is removed from thereloader 130, or prior to the container 150 being removed from thereloader 130, the hatch 152 may be automatically closed via thereleasing mechanism. In embodiments, the weight of the container 150 maybe indicated on the container 150, using, e.g., an RFID tag, anelectronic display meter, and/or using other means.

The reloader 130 may further include an enclosure 148 that generallywraps around the bulk material storage bin 110 and the top of thereloader 130 to control silica dust generated by the moving proppant. Inembodiments, the enclosure 148 may include a vacuum unit 149 for furtherfiltering the air around the reloader 130.

The reloader 130 may be generally configured as a trailer for easytransport. Accordingly, the reloader may include a plurality of wheels144 and a hitch 146 for connecting to a vehicle as is known to those inthe art. The wheels 144 may be built into the trailer such that when thereloader 130 is in the working position, the bottom surface 135 contactsthe ground and the wheels 144 are non-weight bearing. In embodiments,the reloader 130 may be a skid mounted unit that is transported on aseparate trailer.

FIG. 4 shows the discharging device 104B of the transloader 104 in moredetail. In embodiments, the discharging device 104B may have proppantdispensing arms 105A, 105B, and 105C, and so on. While three arms105A-105C are shown in FIG. 4 , one of skill in the art will understandthat the discharging device 104B may include a greater or fewer numberof arms.

In some embodiments, the arms 105A-105C may be movable. The movement ofthe arms 115A-115C may be effectuated manually or using automateddevices (e.g., using actuating devices controlled by the automatedcontrol system 200). A proppant dispensing arm (e.g., arm 105A) may bemoved and resituated to cause that arm to dispense proppant P into theappropriate area of the bulk material storage bin 110 (e.g., to causearm 105A to dispense proppant P into section 115B instead of section115A). In embodiments, the slope of the arms 105A-105A may beadjustable, e.g., may be increased when the proppant P is wet proppantWP to facilitate the transfer of the wet proppant WP from thetransloader 104 to the bulk material storage bin 110. The distal ends ofthe arms 105A-105C may be provided with a diffuser or spreader, e.g., awitch's hat, to ensure that the proppant P is distributed into the bulkmaterial storage bin 110, and specifically the sections 115A-115Cthereof, relatively evenly.

Attention is now directed to FIG. 6 , which schematically illustrates anautomated control system 200 for controlling the reloading system 100.The system 200 includes a computing device 210 communicatively coupled(e.g., via wires or wirelessly over a network 205) to the transloader104, the bulk material storage bin 110, the reloader 130, and optionallyother computing devices. The computing device 210 includes a processor215 communicatively coupled to a network interface 220, at least oneinput/output device 225, and memory 230. The processor 215 operatessoftware 235 housed in the memory 230.

Processor 215 represents one or more digital processors. In some exampleembodiments, the processor 215 may be configured through particularlyconfigured hardware, such as an application specific integrated circuit(ASIC), field-programmable gate array (FPGA), etc., and/or throughexecution of software to perform functions in accordance with thedisclosure herein. Network interface 220 may be implemented as one orboth of a wired network interface and a wireless network (e.g., Wi-Fi,Internet, Bluetooth, Cellular, etc.) interface, as is known in the art.

The input/output device 225 may include one or more input and/or outputdevices which may be embodied in a single device or multiple devices.The input/output device 225 may include a keyboard, a mouse, a styluspen, buttons, knobs, switches, and/or any other device that may allow auser to provide an input to the system 200 via the computing device 210.In some embodiments, the input/output device 225 may comprise a mediaport (such as a USB port, or a SD or microSD port) to allow for media(e.g., a USB drive, a SD or microSD drive, laptop memory, smart phonememory, etc.) to be communicatively coupled to the computing device 210.The input/output device 225 may further include one or more visualindicators (e.g., a display), audible indicators (e.g., speakers), orany other such output device now known or subsequently developed. A usermay functionally interact with the system 200 via the input/outputdevice 225.

Memory 230 represents one or more of volatile memory (e.g., RAM) andnon-volatile memory (e.g., ROM, FLASH, magnetic media, optical media,etc.). Although shown within the computing device 210, memory 230 maybe, at least in part, implemented as a network storage that is externalto the computing device 210 and accessed via the network interface 220.The memory 230 may house software 235, which may be stored in atransitory or non-transitory portion of the memory 230. Software 235includes machine readable instructions that are executed by processor215 to perform the functions described herein. Memory 230 mayadditionally house a database 240 which may include, for example,information relating to features of the containers (e.g., specificfeatures of specific containers such as the weight of an empty/fullPropX® container, or general features such as the average weight of anempty/full, non-specific container). The database 240 may compriseadditional information required to operate the system 100, such as theappropriate rate of flow of wet proppant WP and dry proppant DP into thecontainers 150, the funnel wall section 111A and 111B angles for wetproppant WP and dry proppant DP, the appropriate speed of the conveyerbelt 104A based on the moisture content of the proppant P, et cetera.

The computing device 210 may selectively communicate over the network205 with the transloader 104, the bulk material storage bin 110, and thereloader 130. The computing device 210 may further communicate withother components, such as a mobile device of an operator, and inembodiments, may cause operational data to be stored at a remotelocation, e.g., on the cloud.

In operation, the processor 215 of the computing device 210 maycommunicate with controllers associated with each of the transloader104, the bulk material storage bin 110, and the reloader 130. In someembodiments, some or all of the functionality of the controllersassociated with the transloader 104, the bulk material storage bin 110,and the reloader 130 may be incorporated in the controller 215 of thecomputing device 210. The computing device 210 may be situated withinthe system 100 (e.g., within an enclosure created in the reloader 130 orelsewhere) or may be remote from the system 100.

As described above, the transloader 104 may have a conveyer belt 104A, adischarge device 104B, a moisture sensor 104C, and a processor 104D. Theconveyer belt 104A, the discharge device 104B, and the moisture sensor104C may be in data communication with the processor 104D. The processor104D may further be communicatively coupled to a network interface220T,which may in-turn be coupled over the network 205 to the processor215 of the computing device 210. In operation, the processor 215 mayemploy the software 235 and the processor 104D to control thetransloader 104. For example, where the processor 215 determines thatthe bulk material storage bin 110 is nearing capacity, the processor 215may, via the software 235 and the processor 104D, slow down the speed ofthe conveyer belt 104A. Similarly, the processor 215 may employ thesoftware 235 and the processor 104D to facilitate discharging ofproppant P by the discharging device 104B into the appropriate section115A-115C of the bulk material storage bin 110. The readings of themoisture sensor 104C may be communicated by the processor 104D to theprocessor 215; and, where the angled wall sections 111A and 111B areadjustable, the processor 215 may adjust these angled wall sectionsbased on the moisture content of the proppant P, to ensure suitabledelivery of the proppant (e.g., wet proppant WP) into the container 150.

The bulk material storage bin 110, as described above, may comprisemeasurement devices 113A, actuating devices 113B, regulators 118,loading tubes 120, and a processor 113C. The processor 113C maycommunicate via a network interface 220B with the processor 215, and theprocessor 215 may control the operation of the bulk material storage bin110 and/or other components based on the software 235. For example,where a measurement device 113A indicates that the proppant P is notbeing conveyed to the respective container 150 at a desirable rate(e.g., is jammed), the processor 215 may cause the actuating device 113Bto be activated and/or cause the regulator 118 to more fully open thegate 116. Or, for instance, where a measurement device 113A indicatesthat the bulk material storage bin 110 or a section 115A-115C thereof isoverfull, the processor 215 may halt the conveyer belt 104A and generatean alarm. As another example, the processor 215 may, using the software235, cause the loading tube 120 to expand downwardly into a container150 for dispensing the proppant P therein.

The reloader 130, as detailed above, may include a load cell 142 and alight 155. The reloader may further comprise a processor 130C and anetwork interface 220R to allow for bidirectional communication betweenthe reloader 130 and the processor 215. For example, where the load cell142 indicates that the container 150 is empty and ready to be refilled,the processor 215 may use this information to cause the regulator 118 toopen the gate 116 and start the refilling process. Similarly, theprocessor 215 may cause the regulator 118 to close the gate where theload cell 142 indicates the container 150 is full (e.g., has reached aweight of a full container 150 as set forth in the database 240), orpartially open or close the gate based on the actual versus desired flowrate of proppant P into the container.

Thus, the automated control system 200 may control one or morecomponents of the transloader 104, the bulk material storage bin 110,and the reloader 130, to ensure that the containers 150 are refilled asdesired.

FIG. 7 is a flow chart generally illustrating the application ofsoftware 235 for controlling the system 100. At step 702, the processbegins. Optionally, at step 703, a user inputs (e.g., via theinput/output device 225 or a remote device) information about thecontainer 150 (e.g., selects a type of container such that the computingdevice 210 can pull relevant data from the database 240). At step 704, acontainer 150 is received onto the load cell 142 and the loading tube120 lowers to the container 150. The load cell 142 registers the weightof the container 150 at step 706, and the weight of the container 150 issent to the computing device 210 (or is requested by the computingdevice 210) at step 708.

At step 710, the computing device 210 compares the weight of thecontainer 150 as determined by the load cell 142 to the expected weightof a full container 150 as stored in the database 240. If the weight ofthe container 150 is less than the expected weight of a full container150, the computing device 210 controls the components of the system 100to facilitate efficient reloading of the container 150.

Step 712 may comprise one or more of a plurality of sub-steps, asdescribed in greater detail herein. For example, step 712 may includecausing the regulator 118 to partially open, partially close, or fullyopen the gate 116, activating the actuating devices 113B to urgeproppant P into the container 150 where it is determined the proppant Pis not flowing into the container 150 at a desirable rate, altering theangles of the wall sections 111A and/or 111B based on the moisturecontent of the proppant P, regulating the speed of the conveyer belt104A, et cetera.

Steps 706-712 are repeated until the load cell 142 registers that theweight of the container 150 is approaching the expected weight of a fullcontainer 150, as outlined in the database 240. When the load cell 142registers that the weight of the container 150 is approaching theexpected weight of a full container 150, the process moves to step 714,where the position of the gate 116 is adjusted to slow the rate of theproppant P from the bulk material storage bin 110 to the container 150.Step 714 may be repeated as necessary until the load cell 142 determinesthat the container is full, at which point the process moves to step716. At step 716, the tube 120 may be retracted. Then, at step 718, thehatch 152 on the container 150 may be closed. Finally, at step 720, thelight 155 on the reloader 130 at the corresponding reloading bay 140 isactivated to signal that the container 150 is ready to be removed fromthe reloader 130. When the container 150 is removed from the reloadingbay 140, the process starts over. The process may begin again at step703 with information being input into the system, or the process mayskip to step 704 with a container 150 being loaded into a reloading bay140 for filling. At each step in the process, relevant information, suchas the weight of the container 150, may be displayed via theinput/output device 225 of the one or more computing devices 210.

Each of the various components described herein may be powered using anexternal power source, such as a generator, a turbine, or pulling frompowered system such as a containerized sand belt. However, any powersource, or multiple power sources, may be utilized to provide power tothe system.

By incorporating a system for reloading containerized sand units 150 asdescribed herein, it may be possible to reduce the containerized sandfootprint at the wellsite by reducing the number of containers needed bymore than 30%. With fewer containers at the wellsite, it may be easierto track the containers at the wellsite. Additionally, it may bepossible to reduce the amount of space required to operate the system100 as compared to standard container systems.

Many different arrangements of the various components depicted, as wellas components not shown, are possible without departing from the spiritand scope of the disclosure. Embodiments of the disclosure have beendescribed with the intent to be illustrative rather than restrictive.Alternative embodiments will become apparent to those skilled in the artthat do not depart from its scope. A skilled artisan may developalternative means of implementing the aforementioned improvementswithout departing from the scope of the disclosure. It will beunderstood that certain features and subcombinations are of utility andmay be employed without reference to other features and subcombinationsare and contemplated within the scope of the disclosure.

What is claimed is:
 1. A system for reloading a container with proppant,comprising: a transloader having a conveyer belt and a discharge device;and a reloading system, comprising: a reloader, comprising: arectangular frame comprising a bottom surface and a back surface, a topand a front of the frame being generally open, and at least one dividerthereby defining a plurality of reloading bays, each reloading bay beingconfigured to receive a container; a load cell disposed in each of theplurality of reloading bays; and an indicator in operable communicationwith the load cell; and a bulk material storage bin configured to bepositioned atop the reloader, the bulk material storage bin comprising:a proppant receiving area comprising a plurality of funnels and aproppant dispensing device extending from each of the plurality offunnels, each of the proppant dispensing devices comprising anexpandable loading tube with a diffuser at a distal end thereof and agate for controlling the flow of the proppant from the proppantreceiving area and through the expandable loading tube; wherein arespective proppant dispensing device of the plurality of proppantdispensing devices is configured to extend downwardly into the frame foreach of the plurality of reloading bays; wherein: the transloaderdischarge device is configured to selectively discharge proppant intothe proppant receiving area of the bulk material storage bin; the bulkmaterial storage bin is configured to selectively discharge proppantinto the container; the load cell determines an amount of proppantdischarged into the container from the bulk material storage bin; theindicator is activated when the load cell determines the amount ofproppant discharged into the container from the bulk material storagebin is at a predetermined threshold; and at least one of the funnels hasan angled surface, an angle of the angled surface being selectable basedon a moisture content of the proppant.
 2. The system of claim 1, whereinthe bulk material storage bin comprises a partition thereby defining aplurality of proppant receiving areas, each proppant receiving areacomprising at least one funnel.
 3. The system of claim 2, wherein thetransloader discharge device is configured to selectively dischargeproppant into each of the plurality of proppant receiving areas.
 4. Thesystem of claim 1, further comprising an actuating device in operablecommunication with the bulk material storage bin and configured to urgethe proppant into the container.
 5. The system of claim 4, wherein theactuating device is a vibration device.
 6. The system of claim 4,wherein the bulk material storage bin further comprises a measurementdevice for determining a characteristic of the proppant.
 7. The systemof claim 6, further comprising a computing device in operablecommunication with the actuating device and the measurement device,wherein the computing device is configured to control flow of theproppant out of the bulk material storage bin.
 8. The system of claim 7,wherein the measurement device is selected from the list consisting of:a contact and/or non-contact height sensor, a volume determining device,a radar level measurement device, a mechanical height sensor, anultrasonic level sensor, and a LIDAR volume sensor.
 9. The system ofclaim 7, wherein the computing device is further in operablecommunication with the gate, and wherein the computing device controls aposition of the gate for controlling flow of proppant out of the bulkmaterial storage bin.
 10. The system of claim 1, wherein said reloaderincludes an enclosure and a vacuum unit.
 11. A system for reloading acontainer with a proppant, comprising: a reloader, comprising: arectangular frame comprising a bottom surface and a back surface, a topand a front of the frame being generally open, and at least one dividerthereby defining a plurality of reloading bays; a load cell disposed ineach of the plurality of reloading bays; and an indicator in operablecommunication with the load cell; and a bulk material storage binconfigured to be positioned atop the reloader, the bulk material storagebin comprising: a proppant receiving area comprising a plurality offunnels and a proppant dispensing device extending from each of theplurality of funnels, each of the proppant dispensing devices comprisingan expandable loading tube with a diffuser at a distal end thereof and agate for controlling the flow of the proppant through the expandableloading tube; wherein a respective proppant dispensing device of theplurality of proppant dispensing devices is configured to extenddownwardly into the frame for each of the plurality of reloading bays;wherein each funnel comprises a plurality of angled wall sections; andwherein an angle of each of the plurality of angled wall sections isindependently adjustable based on the characteristics of the proppant.12. The system of claim 11, further comprising a regulator in operablecommunication with the load cell and the gate of the proppant dispensingdevice, wherein the regulator controls flow of proppant through theproppant dispensing device by adjusting the position of the gate basedon information received from the load cell.
 13. The system of claim 11,wherein the bulk material storage bin further comprises a measurementdevice for determining a characteristic of the proppant and an actuatingdevice.
 14. The system of claim 11, wherein said reloader includes avacuum unit.
 15. A system for reloading a container with a proppant,comprising: a reloader, comprising: a rectangular frame comprising abottom surface and a back surface, a top and a front of the frame beinggenerally open, and at least one divider thereby defining a plurality ofreloading bays; a load cell disposed in each of the plurality ofreloading bays; and an indicator in operable communication with the loadcell; and a bulk material storage bin configured to be positioned atopthe reloader, the bulk material storage bin comprising: a proppantreceiving area comprising a plurality of funnels and a proppantdispensing device extending from each of the plurality of funnels, eachof the proppant dispensing devices comprising an expandable loading tubewith a diffuser at a distal end thereof and a gate for controlling theflow of the proppant through the expandable loading tube; wherein arespective proppant dispensing device of the plurality of proppantdispensing devices is configured to extend downwardly into the frame foreach of the plurality of reloading bays; wherein each funnel comprises aplurality of angled wall sections; wherein the bulk material storage binfurther comprises a measurement device for determining a characteristicof the proppant and an actuating device; and wherein an angle of each ofthe plurality of angled wall sections is automatically independentlyadjustable via the actuating device based on the characteristic of theproppant as determined by the measurement device.
 16. The system ofclaim 15, further comprising a regulator in operable communication withthe load cell and the gate of the proppant dispensing device, whereinthe regulator controls flow of proppant through the proppant dispensingdevice by adjusting the position of the gate based on informationreceived from the load cell.
 17. The system of claim 15, wherein saidreloader includes a vacuum unit.
 18. A method for reloading a containerwith proppant, comprising: providing a system for reloading containers,comprising: a transloader having a conveyer belt and a discharge device;and a reloading system, comprising: a reloader, comprising: arectangular frame comprising a bottom surface and a back surface, a topand a front of the frame being generally open, and at least one dividerthereby defining a plurality of reloading bays; a load cell disposed ineach of the plurality of reloading bays; and an indicator in operablecommunication with the load cell; and a bulk material storage binconfigured to be positioned atop the reloader, the bulk material storagebin comprising: a proppant receiving area comprising a plurality offunnels and a proppant dispensing device extending from each of theplurality of funnels, each of the proppant dispensing devices comprisingan expandable loading tube with a diffuser at a distal end thereof and agate for controlling the flow of the proppant from the proppantreceiving area and through the expandable loading tube; wherein arespective proppant dispensing device of the plurality of proppantdispensing devices is configured to extend downwardly into the frame foreach of the plurality of reloading bays; wherein: the load celldetermines an amount of proppant discharged into the container from thebulk material storage bin; and the indicator is activated when the loadcell determines the amount of proppant discharged into the containerfrom the bulk material storage bin is at a predetermined threshold;situating a container in at least one of the plurality of loading baysatop the load cell; setting an angle of an angled surface of each of theplurality of funnels based on a moisture content of the proppant;activating the transloader discharge device to discharge proppant intothe bulk material storage bin; causing at least one of the plurality ofexpandable loading tubes to expand towards the container; causing thegate of the at least one of the plurality of proppant dispensing devicesto at least partially open to allow proppant from the bulk materialstorage bin to flow into the container; determining an amount ofproppant in the container via the load cell; causing the gate of the atleast one of the plurality of proppant dispensing devices to close tostop flow of proppant from the bulk material storage bin once the amountof proppant in the container reaches a predetermined threshold; andactivating the indicator once the amount of proppant in the containerreaches the predetermined threshold.
 19. The method of claim 18, furthercomprising providing a computing device having a database, wherein thepredetermined threshold is set based on information from the database.20. The method of claim 18, further comprising adjusting a position ofthe gate based on information received from the load cell, wherein theadjustment alters but does not stop the flow of proppant from the bulkmaterial storage bin to the container.